A method and system for carbon capture and recycling

ABSTRACT

A method for carbon capture and recycling, the method including the steps of: (i) Capturing CO 2  from at least one CO 2  containing input; (ii) Producing a CO 2  feed stream from the captured CO 2 ; and (iii) Reacting the CO 2  feed stream with a H 2  feed stream to produce a methane containing output.

FIELD OF THE INVENTION

The present invention relates to a method and system for carbon capture and recycling, and in particular methods and systems for capturing CO₂ and producing methane, acetylene and/or other hydrocarbons.

BACKGROUND

The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that the prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

Climate change is an important issue on the agenda of governments worldwide. It is proposed that climate change is accelerated by human production of “greenhouse gases”. Greenhouse gases are those which get trapped in the atmosphere and enhance the “greenhouse effect”. In the greenhouse effect, heat is trapped from escaping the earth due to a build up of the greenhouse gases in the atmosphere. Therefore, in seeking to address climate change, several approaches look to reduce green house gas emissions.

Carbon dioxide (CO₂) is one green house gas where emissions are targeted. Several approaches have been developed to capture and/or reduce CO₂ emissions. One such approach is carbon capture and storage whereby CO₂ is captured (e.g. from air, flue gas etc.) and then stored in selected geological rock formations below the earths surface. It will be appreciated that carbon capture and storages can be expensive, and furthermore, no usable products/outputs are produced from the captured CO₂, it is simply captured and stored.

The present invention seeks to provide an approach to reducing CO₂ emissions that also provides industrially applicable products.

SUMMARY OF THE INVENTION

In one broad form, the present invention provides a method for carbon capture and recycling, the method including the steps of: (i) Capturing CO₂ from at least one CO₂ containing input; (ii) producing a CO₂ feed stream from the captured CO₂; and (iii) reacting the CO₂ feed stream with a H₂ feed stream to produce a methane containing output.

In one form, the method further includes the step of (iv) separating the methane containing output so as to at least provide methane and a first waste output.

In one form, the first waste output is thermally treated to provide CO₂ for one of the at least CO₂ containing inputs for step (i).

In one form, one of the at least one CO₂ containing inputs includes air.

In one form, the H₂ feed stream is provided by a water electrolysis process.

In one form, water produced during step (iii) is provided for the water electrolysis process.

In one form, in step (i), CO₂ is captured using a Calcium Oxide based capture process.

In one form, the method further includes the step of: (v) processing methane from the methane containing output to produce acetylene containing output.

In one form, the method further includes the step of (vi) separating the acetylene containing output so as to at least provide acetylene and a second waste output.

In one form, the second waste output is thermally treated to provide CO₂ for one of the at least one CO₂ containing inputs for step (i).

In one form, step (v) includes heating the methane with a thermal plasma reactor.

In one form, the method further includes the step of (vii) processing methane from the methane containing output to produce a hydrocarbon containing output.

In one form, the method further includes the step of (viii) separating the hydrocarbon containing output so as to at least provide one or more preselected hydrocarbon products and a second waste output.

In one form, the second waste output is thermally treated to provide one of the at least one CO₂ containing inputs for step (i).

In one form, step (vii) includes heating the methane, and the methane is heated by a thermal plasma reactor configured such that plasma is provided in feed with the methane.

In a further broad form the present invention provides a system for carbon capture and recycling, the system including a CO₂ capture apparatus configured to capture CO₂ from at least one CO₂ containing input; and a first reactor configured to produce a methane containing output from a CO₂ feed stream derived from the CO₂ capture apparatus and an H₂ feed stream.

In one form, the system further includes: a first separator configured to separate the methane containing output so as to at least provide methane and a first waste output.

In one form the system further includes a thermal treatment apparatus configured to treat the first waste output so as to provide CO₂ containing input for the CO₂ capture apparatus.

In one from, the CO₂ capture apparatus is configured to capture CO₂ from an air input.

In one form, the system further includes a water electrolysis device for producing the H₂ feed stream. In one form the water electrolysis device is configured to receive water for electrolysis produced in the first reactor.

In one form, the CO₂ capture apparatus is a Calcium Oxide based capture apparatus.

In one form, the system further includes: a second reactor configured to received methane produced in the first reactor and to produce an acetylene containing output therefrom.

In one form the system further includes: a second separator configured to separate the acetylene containing output so as to at least provide acetylene and a second waste output.

In one from, the second waste output is fed to the thermal treatment apparatus.

In one form, the second reactor is thermal plasma reactor.

In one from, the system further includes a second reactor configured to received methane produced in the first reactor and to produce a hydrocarbon containing output therefrom.

In one form, the system further includes a second separator configured to separate the hydrocarbon containing output so as to at least provide preselected hydrocarbon products and a second waste output.

In one form, the second waste output is fed to the thermal treatment apparatus.

In one form, the second reactor is a thermal plasma reactor configured provide plasma in feed with the methane.

BRIEF DESCRIPTION OF THE DRAWINGS

This invention may be better understood with reference to the illustrations of embodiments of the invention in which:

FIG. 1 is an overview layout of one example implementation of the method/system;

and

FIG. 2 is an overview of example reactions utilised in one example implementation of the method/system.

FIG. 3 is a flow chart overview of an example implementation of the method/system.

FIG. 4 is an example of CO₂ capture apparatus.

DETAILED DESCRIPTION

Embodiments of the present invention provide methods and systems for carbon capture and recycling. Generally, embodiments provide a method/system for producing hydrocarbons from captured carbon, such as, for example, methane or acetylene. The presently described system captures CO₂, reducing emissions, and produces industrially applicable output in the form of common precursor materials that may be further processed to form a wide range of materials.

In the methods and systems described, carbon dioxide (CO₂) is captured from at least one CO₂ containing input/source. It would be appreciated that CO₂ may be recovered/captured from a large range of sources, such as, for example, from air, incinerator exhaust streams, or industrial plumes etc. It will also be appreciated that CO₂ may be captured using a variety of CO₂ capture devices/systems. In the presently described system/method, CO₂ is typically captured using a calcium oxide (CaO) based apparatus/system. Calcium Oxide (quicklime) based carbon capture devices/systems have advantages in that the calcium oxide is reusable as a carbon capture agent and permits continuous loop processing as per the below reactions

CaO+CO₂→CaCO₃

CaCO₃+ΔT→CaO+CO₂

As above, CaO reacts with CO₂ to form Calcium Carbonate, and subsequent heating of the Calcium Carbonate releases the CO₂, providing the CaO for reuse (see Appendix A).

From captured CO₂, a CO₂ feed stream is produced and fed to a methane producing reactor in combination with a hydrogen (H₂) feed stream. A methane containing output is produced by the methane producing reactor. Typically, the methane producing reactor is a conventional batch reactor. It will be appreciated that the H₂ feed stream may also be provided from a variety of sources. In one example form, H₂ is provided by a water electrolysis process i.e. as per the below reaction

2H₂O+e ⁻→2H₂+O₂

The methane containing output form the methane producing reactor typically includes methane, water and other partial products as per the reaction

CO₂+4H₂→CH₄+2H₂O

The methane containing output is separated to so as to at least provide a substantially pure methane stream and a first waste output stream/recycle stream. It will also be appreciated that separation of the methane containing output may be performed by varying separation devices/methodologies.

The first waste output, is then typically heated by a thermal treatment apparatus (e.g. incinerator) to provide additional CO₂ e.g. as per the below reaction

${{C_{x}H_{y}} + {\left( {x + \frac{y}{4}} \right)O_{2}}}->{{x{CO}}_{2} + {\frac{y}{2}H_{2}O}}$

The additionally produced CO₂ (e.g. by the incineration of soot etc.) may then be re-fed into the system via carbon capture to drive more methane production. Additionally, water produced from the production of methane may be re-fed to the water electrolysis process to drive production of additional H₂. In some examples, excess water may also be used for cooling and steam generated therefrom used to power turbines etc. Accordingly, it will be appreciated that by products from the reactions at each stage of the process can be re-fed into the system to increase the conversion efficiency, minimise waste, and maximise the methane produced.

Methane produced may further be fed into an acetylene producing reactor so as to produce acetylene containing output e.g. as per the reaction

CH₄+ΔT→C₂H₂

Typically, the reaction requires heating to high temperature (7000-8000° C.). The acetylene producing reactor is thus typically thermal plasma type reactor, and may, for example be like or similar to the reactors as described in the publication “Thermal Conversion of Methane to Acetylene Final Report, J. R. Fincke, R. P. Anderson, T Hyde, R. Wright, R. Bewley, D. C. Haggard, W. D. Swank, Published January 2000, Idaho National Engineering and Environmental Laboratory, Idaho Falls, Id. 83415”.

As with the methane containing output, the acetylene containing output may be purified/separated to provide a pure acetylene stream and a second waste output stream/recycle stream. The second waste output stream may also be fed back to the thermal treatment apparatus (e.g. incinerator), so as to provide additional CO₂ to be re-fed/re-captured by the system.

Alternatively or additionally, produced methane may be processed by a reactor to provide varied/random hydrocarbon containing output. The varied hydrocarbon containing output may then be separated by a separator preconfigured to separate out preselected hydrocarbons. The non-selected output may be provided as a waste output/recycle stream that may then be re-fed to the thermal treatment apparatus, so as to again produce additional CO₂ (e.g. by incineration, gasification). The additional CO₂ produced being returned for recapture by the carbon capture device/apparatus. The waste output/recycle stream essentially provides a CO₂ containing input for the carbon capture device/apparatus. Again the recycle streams from the reactor provide that the methane processing is energy efficient, with waste minimised.

The reactor in this variation is typically of thermal plasma type where plasma is provided in feed with the methane. For example, suitable reactors may be as described in the publication “Thermal Conversion of Methane to Acetylene Final Report, J. R. Fincke, R. P. Anderson, T Hyde, R. Wright, R. Bewley, D. C. Haggard, W. D. Swank, Published January 2000, Idaho National Engineering and Environmental Laboratory, Idaho Falls, Id. 83415”.

One example embodiment of the system and method shall now be described with reference to FIG. 1.

A carbon capture apparatus (1) is provided which is configured to receive one or more CO₂ containing inputs/sources. As shown, air may be one of the CO₂ containing inputs. It will also be appreciated a range of alternate CO₂ containing inputs may be provided such as, for example, waste output streams/recycle streams.

The carbon capture apparatus (1) may take a variety of forms, however, typically, the carbon capture apparatus is a calcium oxide based apparatus. Furthermore, it will be appreciated that calcium oxide may be utilised for carbon capture in a variety of differently configured apparatuses.

The carbon capture apparatus (1) is also configured to produce a CO₂ feed gas stream for a methane producing reactor (2).

Typically, the calcium oxide based carbon capture apparatus for use with the present system/method has two preferred configurations. In both configurations, the apparatus typically comprises four chambers with an outlet (e.g. transport tube) for transporting produced CO₂ feed to a methane producing reactor (2).

In a first configuration, calcium oxide is mixed with air (containing CO₂) in the first chamber via mass transport via air with alternating fans to maximise dispersion and surfaces exposed to the air. CO₂ is captured from the air. In the second chamber, a vacuum is formed, and in the third chamber, the now calcium carbonate is baked to 700° C. whilst being stirred (to speed the process). Carbon dioxide is released and flows through outlet to methane producing reactor. A fourth chamber maintains the vacuum between chambers 2, 3, and 4, before the calcium oxide is reused and air rated once more in chamber 1. This is a continuous closed loop.

In a second configuration, calcium oxide is hydrated with water in the first chamber, with air jets on the bottom bubbling air through the mixture while it is pushed along via a spiral configuration. Chamber 2 creates a vacuum and then raises the temperature to 400° C. removing the water, which is fed to chamber 4. In chamber 3, the product is heated to 700° C. while being stirred to release the carbon dioxide to the methane producing reactor. The calcium oxide is then sent to chamber 4, where it is re-hydrated before returning chamber 1 again. Once again, this is a closed loop full of calcium oxide.

Another example configuration of a carbon capture described at FIG. 4.

As shown in FIG. 1, H₂ gas is provided to the methane producing reactor to combine with CO₂ feed for the production of methane as per the below equation

CO₂+4H₂→CH₄+2H₂O

It will be appreciated that the reactor (2) provides the appropriate conditions for the production of methane and water from CO₂ and H₂ (e.g. heating at >600° C. at 1 atmosphere of pressure). Typically, the reactor is heated to about 800° C. Typically the methane producing reactor is a conventional batch rector. It will also be appreciated that the efficiency of this process may be improved by adjusting the reaction conditions such as, for example, by increasing the pressure of the system and the temperature.

The H₂ feed stream may come from a variety sources. In the example of FIG. 1, the H₂ feed stream is provided by a water electrolysis device (7) which provides H₂ as per the following equation

2H₂O+e ⁻→2H₂+O₂

As water is produced as a by product in the production of methane, the water can be redirected back to the water electrolysis device (7) for re-use (as shown). In other forms, the water may be used for cooling and/or quenching in subsequent process steps or at other at other parts of the system. Oxygen produced in the electrolysis may be utilised for cleaner combustion in other parts of the system or released to the environment. In some forms, the electrolysis reaction is conducted in a U shaped reactor with a simple barrier with the possible addition of an electrolyte to speed the reaction and lower the energy costs.

A first separator (3) is provided to separate the methane, water and other partial products produced in the methane producing reactor (2). Typically separation is achieved via distillation however it will be appreciated that other methods may be used. Any non-methane and non-water products are separated out into a first waste output and fed to a thermal treatment apparatus (4). The thermal treatment apparatus is typically an incinerator, although, it will be appreciated that it may take other forms such as, for example, a gasifier. Thermal treatment, e.g. incineration, results in additional CO₂ product which can then be re-fed to the carbon capture device.

The purified methane from the first separator (3) is directed for further processing to an acetylene producing reactor (5). The acetylene producing reactor (5) provides appropriate reaction conditions to product acetylene form the incoming methane feed stream. Typically, the acetylene is produced via heating as per to the following reaction

CH₄+ΔT→C₂H₂

In one form, the reactor is a thermal plasma type reactor. In one form, the reactor utilises argon plasma to provide temperatures of about 8000° C. and rapid quenching follows to produce the acetylene. Example reactor/process are described in the publication “Thermal Conversion of Methane to Acetylene Final Report, J. R. Fincke, R. P. Anderson, T Hyde, R. Wright, R. Bewley, D. C. Haggard, W. D. Swank, Published January 2000, Idaho National Engineering and Environmental Laboratory, Idaho Falls, Id. 83415”. Typical yields of acetylene are described in Appendix B. In one example, graphite tubing is utilised in the reactor surrounded by heat exchanges to recapture energy to power the argon plasma jets.

A second separator (6) is used to purify the acetylene containing output, and provide a second waste output/recycle stream (9). Typically separation is achieved via temperature gradient and/or distillation although it will be appreciated a range of appropriate separation methods may be utilised. As with the first waste output stream, the second waste output stream (including soot etc.) is fed to the thermal treatment apparatus (4) for recycling. CO₂ produced at the thermal treatment apparatus (e.g. by incineration) is then fed back into the carbon capture apparatus (1). It will be appreciated that in some forms, heat generated from the thermal treatment apparatus (4) may be used to heat the methane and/or acetylene producing reactors. It is noted that the reaction processes in these reactors are exothermic.

Once purified, the acetylene and/or methane produced by the system/process can be readily converted via conventional processes into different polymers, benzo aromatics and other organic compounds for use in a wide variety of industrial applications.

In alternate forms, the acetylene producing reactor may be configured such that the argon plasma (or the like) may be provided in-feed with the methane. This typically results in varied hydrocarbon products being formed rather than mainly acetylene. It will be appreciated that in such examples, the second separator (6) would be configured to filter preselected hydrocarbon products. The remaining non-selected products would be re-fed to the thermal treatment apparatus (e.g. incinerator) for recycling. Again any produced CO₂ from combustion/gasification may re-captured for further methane production.

The presently described system/method has significant advantages over conventional carbon capture and storage approaches for reducing CO₂ emissions. In particular, there are minimal waste products as the recycle feeds (i.e. waste output streams) push the conversion rate towards 100%.

In addition, once purified, acetylene has many industrial applications and can be further processed and converted, for example, into different polymers, benzo aromatics and other organic compounds. Methane may also be extracted from the system to produce compounds other than those produced by reacting acetylene.

It will be appreciated that power for the various components/reactions may be provided/supplemented by mains electricity, renewable energy sources and waste combustion.

In particular, it will be appreciated that due to the configuration of the system, organic waste material can be directly combusted (e.g. in the thermal treatment apparatus) and filtered to provide the CO₂ for the carbon capture. Furthermore, the heat from the combustion also may be supplied to the methane and acetylene producing reactors.

Furthermore, as the methane and acetylene producing reactors are running exothermic processes, once heated, excess energy therefrom may be utilised to further provide electrical energy to the system, while energy recycling may also be used on the coolant for the argon plasma jets. Excess energy may also be harvested by steam turbines to power the argon plasma reactions.

Optional embodiments of the present invention may also be said to broadly consist in the parts, elements and features referred to or indicated herein, individually or collectively, in any or all combinations of two or more of the parts, elements or features, and wherein specific integers are mentioned herein which have known equivalents in the art to which the invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

Although a preferred embodiment has been described in detail, it should be understood that various changes, substitutions, and alterations can be made by one of ordinary skill in the art without departing from the scope of the present invention.

It will be appreciated that various forms of the invention may be used individually or in combination.

APPENDIX A

Calcium oxide is usually made by the thermal decomposition of materials, such as limestone or seashells, that contain calcium carbonate (CaCO3; mineral calcite) in a lime kiln. This is accomplished by heating the material to above 825° C. (1,517° F.), [6] a process called calcination or lime-burning, to liberate a molecule of carbon dioxide (CO₂), leaving quicklime.

CaCO3(s)→CaO(s)+CO₂(g)

The quicklime is not stable and, when cooled, will spontaneously react with CO₂ from the air until, after enough time, it will be completely converted back to calcium carbonate unless slaked with water to set as lime plaster or lime mortar.

APPENDIX B Conver- Maximum Hydrocarbon Minimum sion Acetylene Yield other Normalized SER kW- Reactor Feed- Plasma Quench Effi- Yield than Acetylene Acetylene Soot hr/k_(g) - Reference Year Process Size stock Gas Method ciency y_(C2H2) y_(HC) Yield y_(C2H2) Yield C₂H₂ Leutner & 1961 DC 6.8 kW CH₄ Ar Wall 92.9%  80.1 not 86.2 5.7% 72.5 Stokes plasma heat analyzed jet transfer Gladisch 1962 Huels 8 MW natural CH₄ Water 70.5%  51.4%  45.9% 72.9%  2.7% 12.1 DC arc gas spray Anderson 1962 DC <10 kW CH₄ H₂ Water >90% 76% not 88% not 9.16 & Case plasma spray analyzed analyzed jet Holmes 1969 DuPont 9 MW CH₄ H₂ not not 70% not not 8.8 DC arc reported reported reported reported Ibberson 1976 DC <10 kW CH₄ Ar Wall >90% 82% not 91% not 9.0 & Sen plasma heat reported analyzed jet transfer Plotczyk 1983 DC 10-40 kW CH₄ H₂ Wall  95% 80% not 84% not 15.5 plasma heat analyzed analyzed jet transfer Kovener 1983 RF 4 kW CH₄ & He Wall not not not — not 88 plasma natural heat reported reported reported reported gas transfer Plotczyk 1985 DC 4-16 kW CH₄ Ar Wall >90% 86% not 95% not 23.9 plasma heat reported reported jet transfer 

1-30. (canceled)
 31. A method for recycling CO₂ from CO₂ containing inputs to produce hydrocarbon products, the method including the steps of: capturing CO₂ from at least one CO₂ containing input; (ii) producing a CO₂ feed stream from the captured CO₂; (iii) reacting the CO₂ feed stream with a H₂ feed stream to produce a methane containing output; and (iv) separating the methane containing output so as to at least provide methane and a first waste output, wherein the first waste output is incinerated or gasified to provide one of the at least one CO₂ containing inputs for step (i).
 32. A method as claimed in claim 31, wherein one of the at least one CO₂ containing inputs includes air.
 33. A method as claimed in claim 31, wherein one of the at least one CO₂ containing inputs is derived from incinerator exhaust streams or industrial plumes.
 34. A method as claimed in claim 31, wherein the H₂ feed stream is provided by a water electrolysis process.
 35. A method as claim in claim 34, wherein water produced during step (iii) is provided for the water electrolysis process.
 36. A method as claimed in claim 31 wherein, in step (i), CO₂ is captured using a Calcium Oxide sorbent.
 37. A method as claimed in claim 31, further including the step of: (v) processing methane from the methane containing output to produce acetylene containing output.
 38. A method a claimed in claim 37, further including the step of (vi) separating the acetylene containing output so as to at least provide acetylene and a second waste output.
 39. A method as claimed in claim 38, wherein the second waste output is incinerated or gasified to provide one of the at least one CO₂ containing inputs for step (i).
 40. A method as claimed in claim 39, wherein step (v) includes heating the methane with a thermal plasma reactor.
 41. A method as claimed in claim 31, further including the step of (v) heating methane from the methane containing output with a thermal plasma reactor to produce a hydrocarbon containing output, wherein the thermal plasma reactor is configured such that plasma is provided in feed with the methane.
 42. A method a claimed in claim 41, further including the step of (vi) separating the hydrocarbon containing output so as to at least provide one or more preselected hydrocarbon products and a second waste output.
 43. A method as claimed in claim 42, wherein the second waste output is incinerated or gasified to provide one of the at least one CO₂ containing inputs for step (i).
 44. A system for recycling CO₂ from CO₂ containing inputs to produce hydrocarbon products, the system including: a CO₂ capture apparatus configured to capture CO₂ from at least one CO₂ containing input; a first reactor configured to produce a methane containing output from a CO₂ feed stream derived from the CO₂ capture apparatus and an H₂ feed stream; a first separator configured to separate the methane containing output so as to at least provide methane and a first waste output; and an incinerator configured to combust the first waste output and to thereby provide CO₂ containing input for the CO₂ capture apparatus.
 45. A system as claimed in claim 44, wherein the CO₂ capture apparatus is configured to capture CO₂ from an air input.
 46. A system as claimed in claim 44, wherein the CO₂ capture apparatus is configured to capture CO₂ from incinerator exhaust streams or industrial plumes.
 47. A system as claimed in claim 44, further including a water electrolysis device for producing the H₂ feed stream.
 48. A system as claimed in claim 47, wherein the water electrolysis device is configured to receive water for electrolysis produced in the first reactor.
 49. A system as claimed in claim 44, wherein the CO₂ capture apparatus is a Calcium Oxide based capture apparatus.
 50. A system as claimed in claim 44 further including: a second reactor configured to received methane produced in the first reactor and to produce an acetylene containing output therefrom.
 51. A system as claimed in claim 50, further including: a second separator configured to separate the acetylene containing output so as to at least provide acetylene and a second waste output.
 52. A system as claimed in claim 51, wherein the second waste output is fed to the incinerator.
 53. A system as claimed in claim 50, wherein the second reactor is thermal plasma reactor.
 54. A system as claimed in claim 44 further including: a thermal plasma reactor configured to receive methane produced in the first reactor and to produce a hydrocarbon containing output therefrom, wherein the thermal plasma reactor is configured to provide plasma in feed with the methane.
 55. A system as claimed in claim 54, further including: a second separator configured to separate the hydrocarbon containing output so as to at least provide preselected hydrocarbon products and a second waste output.
 56. A system as claimed in claim 55, wherein the second waste output is fed to the incinerator. 